Polymer Concrete

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  • Polymer concrete is part of group of concretes that use polymers to supplement or replace cement as a binder. The types include polymer-impregnated concrete, polymer concrete, and polymer-Portland-cement concrete.

  • In polymer concrete, thermosetting resins are used as the principal polymer component due to their high thermal stability and resistance to a wide variety of chemicals. Polymer concrete is also composed of aggregates that include silica, quartz, granite, limestone, and other high quality material.

  • Polymer concrete may be used for new construction or repairing of old concrete. The adhesion properties of polymer concrete allow patching for both polymer and cementitious concretes.

  • The low permeability of polymer concrete allows it to be used in swimming pools, sewer pipes, drainage channels, electrolytic cells for base metal recovery, and other structures that contain liquids. It can also be used as a replacement for asphalt pavement, for higher durability and higher strength.

  • Polymer concrete (PC) continues to be widely used as a repair material for concrete.
    Depending upon the method of monomer incorporation into the concrete, the polymer concrete is termed as i. polymer impregnated concrete, when dried precast concrete is impregnated with monomer and polymerized in-situ.
    ii. polymer cement concrete, when cement, aggregate, water and monomer are mixed together and polymerized after laying and.
    iii. polymer concrete, when aggregate and monomer are mixed together and polymerized after laying.

  • Polymer Concrete products have been used for decades in engineering constructions like machine basis for high precision milling machines, in the building industry for facade products and sanitary parts, in electrical engineering for isolation devices and especially in the chemical industry for all types of ducts due to its favourable properties.

  • Due to the high chemical resistance, especially the resistance against hydrogen sulfides, polymer concrete products have found favor in sewer installation and rehabilitation projects.

  • In the bridge design, an aluminium alloy bridge deck is used with a polymer concrete wearing surface.
    It is similar to ordinary cement concrete because it contains fine and coarse aggregates, but the hydraulic binder is totally substituted with a polymer material. The aggregates are bounded together by polymer matrix. It contains no cement or water.

  • It can be reinforced with fibers like : glass, carbon, boron or natural fibers like coconut , sugar cane bagasse, cellulose.

  • The Autocaster continuous casting machine automates the production of polymer concrete matrix for cast polymer concrete manufacturing.

  • Polymer concrete is an expensive overlay material. It not only improves the abrasion and skid resistance of the deck surface, it also protects against corrosion of steel reinforcement.

  • It is impermeable to water, deicing salts, and chemicals that can accelerate corrosion. This protective capability can significantly reduce future bridge deck maintenance and repair costs.

  • The two main components of polymer concrete, resin binder and aggregate both contribute to the material's durability and protective qualities.

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